Saw blade

Abstract

A reciprocating saw blade includes a body defining a longitudinal axis. The saw blade includes an attachment portion coupled to the body. The attachment portion is able to couple to a reciprocating saw. The saw blade further includes a cutting portion having a plurality of cutting teeth. Each cutting tooth includes a tip and a protrusion spaced a first distance from the tip. The protrusion of a respective cutting tooth is spaced a first distance from the tip of the cutting tooth in a direction parallel to the longitudinal axis. A gullet is defined between the tip of a first cutting tooth and the protrusion of an adjacent second cutting tooth. The gullet includes a gullet width in a direction parallel to the longitudinal axis. The first distance is greater than the gullet width.

The invention claimed is: 
     
       1. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising:
 a body defining a longitudinal axis; 
 an attachment portion coupled to the body, the attachment portion configured to couple to the reciprocating saw; 
 a cutting portion formed on the body, the cutting portion including 
 a plurality of cutting teeth, each cutting tooth including a tip and a rounded protrusion, the rounded protrusion of a respective cutting tooth spaced a first distance from the tip of the cutting tooth in a direction parallel to the longitudinal axis, the tip of the cutting tooth being closer than the rounded protrusion of the cutting tooth to the attachment portion along a direction parallel to the longitudinal axis; and 
 a gullet defined between the tip of a first cutting tooth and the rounded protrusion of an adjacent second cutting tooth, the gullet including a gullet width in a direction parallel to the longitudinal axis; 
 wherein the first distance is greater than the gullet width; and 
 wherein the gullet is further defined by a rake face of the first cutting tooth, the rake face extending a majority of a depth of the gullet. 
 
     
     
       2. The reciprocating saw blade of  claim 1 , wherein the first distance is defined as extending from the tip of the cutting tooth to an apex of the rounded protrusion. 
     
     
       3. The reciprocating saw blade of  claim 2 , wherein the apex of the rounded protrusion and the tip of the cutting tooth are separated by an offset distance extending in a direction perpendicular to the longitudinal axis, the offset distance being less than or equal to 0.035 inches. 
     
     
       4. The reciprocating saw blade of  claim 3 , wherein the offset distance is 0.032 inches. 
     
     
       5. The reciprocating saw blade of  claim 1 , wherein
 each cutting tooth includes a relief surface, and 
 the relief surface is interrupted by the rounded protrusion of the cutting tooth. 
 
     
     
       6. The reciprocating saw blade of  claim 5 , wherein each cutting tooth includes a first protrusion arc having a first protrusion radius, the first protrusion arc transitioning from the relief surface. 
     
     
       7. The reciprocating saw blade of  claim 6 , wherein each cutting tooth includes
 a first protrusion face that extends from the first protrusion arc, and 
 an apex of the rounded protrusion that extends from the first protrusion face and has a second protrusion radius. 
 
     
     
       8. The reciprocating saw blade of  claim 7 , wherein the gullet is further defined by a gullet surface between the first cutting tooth and the second cutting tooth. 
     
     
       9. The reciprocating saw blade of  claim 8 , wherein the gullet surface extends from the rake face of the first cutting tooth to the rounded protrusion of the second cutting tooth. 
     
     
       10. The reciprocating saw blade of  claim 9 , wherein each cutting tooth includes a second protrusion face extending from the apex of the rounded protrusion to the gullet surface. 
     
     
       11. The reciprocating saw blade of  claim 1 , wherein the gullet width is 0.08 inches. 
     
     
       12. The reciprocating saw blade of  claim 1 , wherein a ratio between the first distance and the gullet width is 1.5. 
     
     
       13. The reciprocating saw blade of  claim 1 , wherein
 each cutting tooth includes a rake face, 
 the rounded protrusion of each cutting tooth includes a second protrusion face, 
 a first imaginary line extends collinear with the rake face, 
 a second imaginary line extends collinear with the second protrusion face, and 
 either the first imaginary line and the second imaginary line intersect at an angle that is less than or equal to 8°, or the first imaginary line and the second imaginary line are parallel to each other. 
 
     
     
       14. The reciprocating saw blade of  claim 1 , wherein
 the gullet is further defined by a gullet surface between the first cutting tooth and the second cutting tooth, and 
 the rake face of the first cutting tooth meets tangentially with the gullet surface. 
 
     
     
       15. The reciprocating saw blade of  claim 14 , wherein the gullet surface meets tangentially with the rounded protrusion of the second cutting tooth. 
     
     
       16. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising:
 a body defining a longitudinal axis; 
 an attachment portion coupled to the body, the attachment portion configured to couple to the reciprocating saw; 
 a cutting portion formed on the body, the cutting portion including
 a plurality of cutting teeth, each cutting tooth including a tip, a relief surface, and a protrusion, each tip spaced a separation distance from a corresponding protrusion in a direction perpendicular to the longitudinal axis, the relief surface directly interrupted by the protrusion, the tip of a respective cutting tooth being closer than the protrusion of the cutting tooth to the attachment portion along a direction parallel to the longitudinal axis; and 
 a gullet defined between the tip of a first cutting tooth and the protrusion of an adjacent second cutting tooth, the gullet including a base; 
 
 wherein the tip is spaced a tip height distance from the base of the gullet in a direction perpendicular to the longitudinal axis; and 
 wherein the separation distance is greater than or equal to 32% of a length of the tip height distance. 
 
     
     
       17. The reciprocating saw blade of  claim 16 , wherein the separation distance is less than or equal to 35% of the length of the tip height distance. 
     
     
       18. The reciprocating saw blade of  claim 17 , wherein the separation distance is 34% of the length of the tip height distance. 
     
     
       19. The reciprocating saw blade of  claim 16 , wherein
 the gullet is further defined by a rake face of the first cutting tooth and a gullet surface between the first cutting tooth and the second cutting tooth, and 
 the gullet surface extends from the rake face of the first cutting tooth to the protrusion of the second cutting tooth. 
 
     
     
       20. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising:
 a body defining a longitudinal axis; 
 an attachment portion coupled to the body, the attachment portion configured to couple to the reciprocating saw; 
 a cutting portion formed on the body, the cutting portion including
 a plurality of cutting teeth, each cutting tooth including a tip and a rounded protrusion, the rounded protrusion of a first cutting tooth spaced a gap distance from the tip of an adjacent second cutting tooth in a direction parallel to the longitudinal axis, the tip of the first cutting tooth being closer than the rounded protrusion of the first cutting tooth to the attachment portion along a direction parallel to the longitudinal axis, and 
 a gullet defined between the tip of a first cutting tooth and the protrusion of an adjacent second cutting tooth, the gullet including a base; 
 
 wherein each cutting tooth defines
 an effective relief surface that extends from the tip and is tangent to the rounded protrusion, the effective relief surface of the first cutting tooth spaced apart from an effective relief surface of the adjacent second cutting tooth by an offset distance extending in a direction perpendicular to the first effective relief surface, 
 a tip height extending in a direction perpendicular to the longitudinal axis from the base of the gullet to the tip of the cutting tooth, and 
 a rake face that extends from the tip toward the longitudinal axis along a majority of the tip height; and 
 
 wherein a ratio of the gap distance to the offset distance is greater than 1.1. 
 
     
     
       21. The reciprocating saw blade of  claim 20 , wherein the ratio of the gap distance to the offset distance is greater than 1.3 and less than or equal to 1.6. 
     
     
       22. The reciprocating saw blade of  claim 21 , wherein the ratio of the gap distance to the offset distance is 1.4.